Fastener delivery and installation system

ABSTRACT

A fastener delivery and installation system is provided that comprises an end effector mounted on an automated machine and operable to drill a hole through a workpiece and insert a fastener through the hole, and a fastener feed unit operable with the automated machine to deliver the fasteners through the end effector and into the workpiece. Further, a hand-held tool is operable against a second surface of the workpiece and is aligned with the end effector. Once the hand-held tool is positioned properly, a magnetic field is generated and the workpiece is clamped to enable the end effector to drill a hole through the workpiece and insert a fastener therethrough. Additionally, a detector is located on the hand-held tool for generating guidance information to inform an operator where to move the hand-held tool so as to align the hand-held tool with the end effector.

FIELD OF THE INVENTION

[0001] The present invention relates generally to fastening equipmentand more particularly to equipment and methods for drilling holesthrough a workpiece, delivering fasteners to the workpiece, andinstalling the fasteners into the holes.

BACKGROUND OF THE INVENTION

[0002] In the production assembly of aircraft, the majority ofsubstructure such as fuselage frames and longerons, along with wingspars and ribs, are joined to the skin of the aircraft with thousands offasteners. Further, a plurality of fastener types, along with variationsin diameters and grip lengths, are typically used in an aircraftassembly or subassembly. (Generally, a fastener grip length refers tothe cumulative thickness of the parts that the fastener holds together).Installation of fasteners in relatively large aircraft substructures andskins is typically performed either manually or by automated fasteningequipment.

[0003] Manufacturing equipment that automatically delivers fasteners toa workpiece, or a fastening device, is typically employed in high rateproduction environments. The equipment generally comprises a storagedevice for the fasteners and a mechanism or system that transportsfasteners from the storage device to the workpiece or fastening device.For example, U.S. Pat. No. 5,588,554 to Jones, the contents of which areincorporated herein by reference in their entirety, discloses a devicefor delivering fasteners to a workpiece comprising a suction head thatremoves fasteners from a storage area and delivers the fasteners througha delivery tube using a vacuum. The fasteners are individually stored inholes of a predetermined or fixed depth, and only one fastener may bestored in any given hole. Accordingly, each hole contains a fastener ofa specific configuration, diameter, and grip length.

[0004] Yet another known art fastener delivery system is disclosed inU.S. Pat. No. 5,193,717 to Rink et al., wherein rivet cartridges areunloaded and rivets are delivered to a rivet machine or the like withpressurized air. The rivet cartridges are filled off line by a rivetpump that receives rivets from a vibrating bowl feeder, and thefasteners are delivered through a common passageway to a fastenerinstallation tool. However, the fastener delivery system of Rink et al.requires a separate fastener escapement mechanism to remove and deliverthe fasteners.

[0005] Additionally, manual fastener installation can be time consumingand cumbersome. Generally, an operator must first determine theappropriate fastener type and diameter from a blueprint or othermanufacturing work instruction delivery system. Due to manufacturingvariations in individual part fabrication and assembly positioningvariations, the proper grip length of the fastener is often determinedby manually measuring hole depths. Once the proper fastenerconfiguration is determined, the fastener stock must then be located andselected from fastener bins, which are typically stored at a commonlocation near the work station. A limited number of fasteners are thenmoved by hand from the fastener bins to the work station and aregenerally staged within the reach of an operator. If permitted by thework environment, several fasteners are stored in a pouch that issecured around the waist of an operator. Accordingly, the operator sortsthrough the fasteners to select the proper configuration and inserts thefastener directly into a hole through the parts or inserts the fastenerinto an installation tool that installs the fastener through the parts.

[0006] As a result, a significant amount of time is spent by an operatordetermining the proper fastener configuration, locating the fastenerwithin a storage bin, and transporting the fastener to the work stationfor installation. In addition, the manual location and staging offasteners introduces an increased risk of foreign object damage (FOD)from a dropped or misplaced fastener, which may result in severe damageto and/or inoperation of certain aircraft systems. Therefore, manualfastener installation procedures are time consuming and may alsoincrease the risk of failure of aircraft systems.

[0007] Accordingly, a need remains in the art for a fastener deliveryand installation system that efficiently delivers and installs fastenersto a work station or workpiece where parts are being assembled. Thefastener delivery and installation system should be capable ofdelivering a plurality of different fastener configurations and shouldfurther be capable of automatically selecting the proper fastenerconfiguration from a variety of inputs. Additionally, the fastenerdelivery system should also be capable of maintaining a record offastener inventory that is preferably integrated with existingproduction manufacturing systems.

SUMMARY OF THE INVENTION

[0008] In one preferred form, the present invention provides anapparatus for delivering and installing fasteners to and through aworkpiece that combines an automated machine and a fastener feed unitdisposed on one side of the workpiece and a hand-held tool that ismanipulated by an operator on the opposite side of the workpiece. Theautomated machine comprises an end effector supporting tools such as adrill for drilling a hole through the workpiece and a riveter forinstalling a rivet into the hole. Additionally, a controller positionsand activates the automated machine, the end effector, and the fastenerfeed unit during operation of the apparatus.

[0009] The fastener feed unit comprises an unloading mechanism incommunication with a fastener storage device, wherein a control systemactivates the unloading mechanism to remove a specific fastenerconfiguration from the fastener storage device and transport thefastener to a delivery conduit, where the fastener is caused to bedelivered through the delivery conduit, through the end effector, andinto a hole in the workpiece, preferably using a pneumatic source. Thefastener storage device is generally a fastener cassette that comprisesa plurality of fastener storage tubes that house the fasteners. Eachfastener storage tube houses a specific fastener configuration, whichincludes the fastener type (i.e. hi-lok, jo-bolt, rivet), diameter, andgrip length. Accordingly, the fastener storage tubes range in diametercorresponding to the specific fastener configuration housed therein.Furthermore, the fastener storage device is removable from the fastenerfeed unit to facilitate ease of replacement when additional types offasteners may be required or when the fastener storage device is movedto another apparatus. Moreover, a plurality of fastener cassettes may beused as necessary within the fastener feed unit.

[0010] The automated machine further comprises a guide structure, suchas a pair of guide rails, adapted to be releasably affixed to oradjacent to the workpiece, along with an end effector carriage and afastener carriage that travel along the guide structure and support theend effector and the fastener feed unit, respectively. Accordingly, theend effector and the fastener feed unit can be positioned in a desiredlocation along the surface of the workpiece where a fastener is to beinstalled. Alternately, the fastener feed unit may be disposed at afixed location while the end effector moves along the guide structure.The end effector further comprises an electromagnetic clamping devicethat generates a magnetic field and a positioning device that generatesa positioning signal detectable on the opposite side of the workpiece.

[0011] The hand-held tool comprises a magnetic clamping block, such as asteel block or the like. When the magnetic clamping block is placedagainst the opposite surface of the workpiece on the side opposite fromthe end effector, the magnetic field of the clamping device causes theclamping block to be attracted toward the clamping device, therebyclamping the workpiece therebetween. The hand-held tool furthercomprises a detector for detecting the positioning signal of thepositioning device, wherein the detector is operable to generateguidance information for an operator. Further, the hand-held tool mayinclude a visual display for displaying the guidance information ingraphical, audible, or other forms. Once the hand-held tool is alignedwith the end effector, the controller activates the end effector and thefastener feed unit to drill a hole in the workpiece and to furtherdeliver and install a fastener into the hole.

[0012] After fastener installation is complete, the end effector isoperable to signal the operator that the operation is complete. Theoperator may then deactivate the hand-held tool such that the automatedmachine (and also the fastener feed unit if required) may be moved to anew location for subsequent fastener installations. Alternately, the endeffector may automatically deactivate the electromagnetic clampingdevice once installation of the fastener is complete such that no actionof the operator is required to release the clamping force on theworkpiece.

[0013] As used herein, the term “workpiece” should be construed by thoseskilled in the art to be one or more parts or workpieces that are beingassembled at a given location, for example a wing spar to a wing skin,or a fuselage frame to a fuselage skin. Accordingly, the term“workpiece” should not be limited to a single part or workpiece.

[0014] Further areas of applicability of the present invention willbecome apparent from the detailed description provided hereinafter. Itshould be understood that the detailed description and specificexamples, while indicating the preferred embodiment of the invention,are intended for purposes of illustration only and are not intended tolimit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

[0016]FIG. 1 is a perspective cutaway view of a fastener delivery andinstallation system in accordance with the present invention;

[0017]FIG. 2 is an enlarged view of a portion of FIG. 1 showing thefastener delivery and installation system in greater detail inaccordance with the present invention;

[0018]FIG. 3 is a perspective view of the fastener delivery andinstallation system in use on a wing box in accordance with the presentinvention;

[0019]FIG. 4 is a block diagram of the fastener delivery andinstallation system in accordance with the present invention; and

[0020]FIG. 5 is a perspective view of a fastener feed unit in accordancewith the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] The following description of the preferred embodiments is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

[0022] Referring to the drawings, an apparatus according to the presentinvention is illustrated and generally indicated by reference numeral 10in FIGS. 1 through 4, which is also referred to as a fastener deliveryand installation system 10. The fastener delivery and installationsystem is comprised of an automated machine 12 for installing fastenersin a workpiece, as shown and described in copending application titled“Apparatus and Method for Installing Fasteners in a Workpiece,” Ser. No.09/522,222, which is commonly assigned with the present application andthe contents of which are incorporated herein by reference. The fastenerdelivery and installation system further comprises a fastener feed unit14, which is shown and described in copending application titled“Portable Automatic Fastener Delivery System,” Ser. No. 09/931,501,which is also commonly assigned with the present application and thecontents of which are incorporated herein by reference.

[0023]FIGS. 1 and 2 show the fastener delivery and installation system10 in use with a fuselage section of an airframe, and FIG. 3 shows thefastener delivery and installation system 10 in use with a wing sectionof an airframe. FIG. 4 is a block diagram of the fastener delivery andinstallation system 10 with its constituent components which aredescribed in greater detail below.

[0024] As shown, the fastener delivery and installation system 10comprises the automated machine 12 and the fastener feed unit 14disposed on one side of the workpiece (i.e., fuselage, wing), alsoreferred to as a first side of the workpiece, and a hand-held tool 16disposed on the other side of the workpiece, or along a second surfaceof the workpiece. The automated machine 12 is preferably supported on aguide structure 18 that advantageously can be releasably attached to theworkpiece. In the illustrated embodiment, the guide structure 18comprises a pair of parallel guide rails 20 affixed to the first surfaceof the workpiece by suction cups 22. The guide structure 18 couldinstead be affixed to the workpiece by bolts or the like, or could besupported without being attached to the workpiece, as long as the guidestructure 18 is fixed relative to the workpiece.

[0025] The automated machine 12 further comprises an end effector 24that is used to perform operations such as drilling a hole through theworkpiece and installing a fastener into the hole. The end effector 24is supported within an end effector carriage 26 that rides along therails 20, and similarly, the fastener feed unit 14 is supported within afastener carriage 28 that also rides along the rails 20. Alternately,the fastener feed unit 14 may be positioned at a fixed location on orproximate the rails 20 while the end effector carriage 26 rides alongthe rails to install subsequent fasteners. The end effector 24advantageously comprises a drill 24 a, a conduit 24 b through whichfasteners are delivered from the fastener feed unit 14, and/or a riveter24 c, which may be an electromagnetic riveter (EMR) or other device foruse in installing other types of fasteners such as hi-loks or jo-bolts,among others. The end effector 24 may also comprise an impact hammer 24d or the like for forcing a lock bolt or similar type of fastenerthrough a hole drilled through the workpiece. Any one of the varioustools 24 a-d of the end effector 24 can be moved into a working positionaligned with a target location on a workpiece where a fastener is to beinstalled, while the other tools are held in stand-by position, and theselected tool can be operated to perform an operation on the workpiece.Operation of the end effector 24 and the hand-held tool 16, includingthe detector, the processor, and the display, among others, is describedin greater detail in copending application Ser. No. 09/522,222, thecontents of which have been incorporated by reference, and thereforesuch operation is not described herein.

[0026] As further shown, the fastener feed unit 14 is in communicationwith the automated machine 12 through a delivery conduit 30, throughwhich fasteners are delivered from the fastener feed unit 14 to theautomated machine 12. Generally, the fasteners are delivered through thedelivery conduit 30, which is preferably a flexible material and thelength of which may be adjusted according to specific applicationrequirements, to the end effector 24 and through the end effectorconduit 24 b for installation through the workpiece.

[0027] Preferably, the hand-held tool 16 comprises a command signalgenerator 32 as shown in FIG. 4, which can be activated by the operator,such as by pulling a trigger or operating a similar type of switchdevice. The command signal generator 32 generates a command signal thatis received by the automated machine 12, and more specifically by acontroller 34 that positions and activates the automated machine 12, theend effector 24, and the fastener feed unit 14. For example, the commandsignal generator 32 may transmit an RF signal, and the controller 34 mayinclude a receiver for receiving the RF signal, thereby facilitatingcommunication between the operator and the controller 34.

[0028] Referring now to FIG. 5, the fastener feed unit 14 according tothe preferred form of the present invention is shown in greater detail.The fastener feed unit 14 comprises an unloading mechanism 40 incommunication with a fastener storage device 42, wherein the controller34 (not shown) causes the unloading mechanism 40 to remove a fastenerhaving a specific configuration from the fastener storage device 42 andtransport the fastener to the delivery conduit 30, wherein the fasteneris delivered to the end effector 24 (not shown). The fastener feed unit14 generally removes and delivers fasteners using a pneumatic source 44,which is preferably 90 psi (pounds per square inch) shop air. Thepneumatic source 44 is activated by the controller 34 and is incommunication with both the unloading mechanism 40 and the deliveryconduit 30 through flexible tubing 46. (The fittings that connect thepneumatic source 44 and the flexible tubing 46 are not shown forclarity). The pneumatic source 44 activates one or a plurality of vacuumgenerators 48 to remove a fastener from the fastener storage device 42and secure the fastener within the unloading mechanism 40. Once thefastener is secured within the unloading mechanism 40, the controller 34positions the unloading mechanism 40 adjacent the delivery conduit 30,wherein the vacuum generators 48 are deactivated and the fastener fallsand is transported through the delivery conduit 30 by gravity and bypressurized air from the pneumatic source 44. Operation of the fastenerfeed unit 14, including the delivery conduit 30, the fastener storagedevice 42, and the unloading mechanism 40, among others, is described ingreater detail in copending application Ser. No. 09/931,501, which hasbeen incorporated by reference, and thus are not further describedherein for purposes of clarity.

[0029] In operation, the controller 34 activates the end effector 24 togenerate a magnetic field for clamping the workpiece between the endeffector 24 and the hand-held tool 16. The controller 34 then activatesthe end effector 24 to drill a hole through the workpiece. After thehole is drilled, the controller 34 activates the fastener feed unit 14to deliver the required fastener through the delivery conduit 30,through the end effector 24, through the end effector conduit 24 b, andinto the hole in the workpiece. Next, the controller 34 activates theend effector 24 to install the fastener in the hole using, for example,the impact hammer 24 d. When installation of the fastener is completed,the controller 34 can signal the operator to deactivate the magneticfield produced by the end effector 24 so that the automated machine 12,and the fastener feed unit 14 if applicable, can be moved along therails 20 to the next location at which a fastener is to be installed.

[0030] The automated machine 12 preferably comprises a powered drivedevice 50 (FIG. 4) for moving the automated machine 12 and/or thefastener feed unit 14 along the rails 20 to a new location. The powereddrive device 50 advantageously is controlled by the controller 34 so asto accurately position the automated machine 12 and/or the fastener feedunit 14 in a predetermined location along the workpiece. Further, thecontroller 34 may comprise a control system as shown and described thecopending application Ser. No. 09/931,501, which has been incorporatedby reference, or the control system may be a separate component of thefastener delivery and installation system 10 that is in communicationwith the controller 34. The design of a suitable controller 34 and/orcontrol system is well within the capabilities of a machine designer ofordinary skill in the art of automated machine design and thus will notbe further described herein.

[0031] Although the present invention discloses a system for thedelivery of fasteners, other types of components may also be removed anddelivered according to the teachings of the present invention for avariety of applications. For example, the system may be employed todeliver detail parts for an assembly or even components for otherapplications such as food delivery, mail delivery, and a wide range ofother applications. Accordingly, the delivery and installation offasteners for aircraft assembly operations shall not be construed aslimiting the scope of the present invention.

[0032] The description of the invention is merely exemplary in natureand, thus, variations that do not depart from the substance of theinvention are intended to be within the scope of the invention. Suchvariations are not to be regarded as a departure from the spirit andscope of the invention.

What is claimed is:
 1. An apparatus for delivering and installingfasteners to and through a workpiece comprising: an automated machinemovable along a first surface of the workpiece; an end effector mountedon the automated machine and operable to drill a hole through theworkpiece and insert a fastener through the hole, the end effectorcomprising an electromagnetic clamping device that generates a magneticfield; a positioning device located proximate the end effector andoperable to generate a positioning signal that is detectable proximate asecond surface of the workpiece on an opposite side from the firstsurface; a fastener feed unit operable with the automated machine todeliver the fasteners through the end effector and into the workpiece; acontroller that positions and activates the automated machine, the endeffector, and the fastener feed unit; a hand-held tool comprising amagnetic clamping block disposed against the second surface of theworkpiece and aligned with the electromagnetic clamping device, whereinwhen the magnetic field is generated, the workpiece is clamped betweenthe magnetic clamping block and the electromagnetic clamping device toenable the end effector to drill a hole through the workpiece and inserta fastener therethrough; and a detector located on the hand-held toolfor detecting the positioning signal and for generating guidanceinformation to inform an operator where to move the hand-held tool so asto align the magnetic clamping block with the electromagnetic clampingdevice.
 2. The apparatus according to claim 1, wherein the fastener feedunit further comprises: a fastener storage device; an unloadingmechanism in communication with the fastener storage device; and adelivery conduit in communication with the unloading mechanism and theautomated machine, wherein the controller activates the unloadingmechanism to retrieve at least one fastener from the fastener storagedevice, thereby causing the fastener to be transported through thedelivery conduit and to the end effector.
 3. The apparatus according toclaim 1, wherein the hand-held tool further comprises a command signalgenerator operable to generate a command signal upon activation by theoperator, and the end effector being operable to receive the commandsignal and to activate the electromagnetic clamping member to generatethe magnetic field such that the electromagnetic clamping member and themagnetic clamping block clamp the workpiece therebetween.
 4. Theapparatus according to claim 1, wherein the hand-held tool furthercomprises a visual display for displaying the guidance information. 5.The apparatus according to claim 1, wherein the automated machinefurther comprises: a guide structure fixed relative to the workpiece,the guide structure comprising at least one guide member extending alongthe first surface; an end effector carriage mounted on the guidestructure and movable along the guide member, the end effector beingmounted on the carriage; and a fastener carriage mounted on the guidestructure and movable along the guide member, the fastener feed unitbeing mounted on the carriage.
 6. The apparatus according to claim 5,wherein the guide structure comprises a pair of parallel guides alongwhich the carriages move.
 7. The apparatus according to claim 5, whereinthe guide structure is releasably attachable to the workpiece.
 8. Theapparatus according to claim 1, wherein the fastener storage devicefurther comprises at least one fastener cassette that is removablydisposed within the fastener feed unit.
 9. The apparatus according toclaim 8, wherein the fastener cassette further comprises a plurality offastener storage tubes that house a plurality of fastenerconfigurations.
 10. An apparatus for delivering and installing fastenersto and through a workpiece comprising: an automated machine movablealong a first surface of the workpiece; an end effector mounted on theautomated machine and operable to drill a hole through the workpiece andinsert a fastener through the hole, the end effector comprising anelectromagnetic clamping device that generates a magnetic field; apositioning device located proximate the end effector and operable togenerate a positioning signal that is detectable proximate a secondsurface of the workpiece on an opposite side from the first surface; afastener feed unit operable with the automated machine to deliver thefasteners through the end effector and into the workpiece; and acontroller that positions and activates the automated machine, the endeffector, and the fastener feed unit.
 11. The apparatus according toclaim 10, wherein the fastener feed unit further comprises: a fastenerstorage device; an unloading mechanism in communication with thefastener storage device; and a delivery conduit in communication withthe unloading mechanism and the automated machine, wherein thecontroller activates the unloading mechanism to retrieve at least onefastener from the fastener storage device, thereby causing the fastenerto be transported through the delivery conduit and to the end effector.12. The apparatus according to claim 10, wherein the automated machinefurther comprises: a guide structure fixed relative to the workpiece,the guide structure comprising at least one guide member extending alongthe first surface; an end effector carriage mounted on the guidestructure and movable along the guide member, the end effector beingmounted on the carriage; and a fastener carriage mounted on the guidestructure and movable along the guide member, the fastener feed unitbeing mounted on the carriage.
 13. The apparatus according to claim 12,wherein the guide structure comprises a pair of parallel guides alongwhich the carriages move.
 14. The apparatus according to claim 12,wherein the guide structure is releasably attachable to the workpiece.15. The apparatus according to claim 10, wherein the fastener storagedevice further comprises at least one fastener cassette that isremovably disposed within the fastener feed unit.
 16. The apparatusaccording to claim 15, wherein the fastener cassette further comprises aplurality of fastener storage tubes that house a plurality of fastenerconfigurations.
 17. A method of installing a fastener in a workpiece,the method comprising the steps of: (a) disposing an automated machineadjacent a first surface of the workpiece such that an electromagneticclamping device of the automated machine is against the first surface;(b) placing a hand-held tool adjacent an opposite second surface of theworkpiece such that a magnetic clamping block of the hand-held tool isagainst the second surface; (c) sending a positioning signal from theautomated machine to the hand-held tool; (d) detecting the positioningsignal at the hand-held tool; (e) aligning the hand-held tool with theelectromagnetic clamping device based on the detected positioningsignal; (f) activating the electromagnetic clamping device after thehand-held tool has been aligned, so as to cause the magnetic clampingblock and the electromagnetic clamping device to be attracted towardeach other and clamp the workpiece therebetween; (g) operating theautomated machine to drill a hole in the workpiece; (h) operating afastener feed unit to deliver a fastener through the automated machineand into the workpiece; and (i) operating the automated machine toinstall the fastener into the hole.
 18. The method according to claim 17further comprising supporting the automated machine and the fastenerfeed unit on a guide structure extending along the first surface of theworkpiece and moving the automated machine and the fastener feed unitalong the guide structure to position the automated machine and thefastener feed unit proximate a location where the fastener is to beinstalled.
 19. The method according to claim 18, wherein the automatedmachine and the fastener feed unit are moved along the guide structureby a powered drive system.
 20. A method of delivering a fastener to aworkpiece, the method comprising the steps of: (a) disposing anautomated machine and a fastener feed unit adjacent a first surface ofthe workpiece such that an electromagnetic clamping device of theautomated machine is against the first surface; (b) transmitting asignal to a control system of the fastener feed unit, the signalcomprising a request for at least one fastener; (c) positioning anunloading mechanism adjacent a fastener storage device within thefastener feed unit; (d) removing at least one fastener from the fastenerstorage device and securing the fastener within the unloading mechanism;(e) positioning the unloading mechanism adjacent at least one deliveryconduit; and (f) causing the control system to deliver the fastenerthrough the delivery conduit, through the automated machine, and intothe workpiece.
 21. The method according to claim 20 further comprisingsupporting the automated machine and the fastener feed unit on a guidestructure extending along the first surface of the workpiece and movingthe automated machine and the fastener feed unit along the guidestructure to position the automated machine and the fastener feed unitproximate a location where the fastener is to be installed.
 22. Themethod according to claim 20, wherein the automated machine and thefastener feed unit are moved along the guide structure by a powereddrive system.
 23. The method according to claim 20 further comprisingthe step of activating a pneumatic source to remove the fastener fromthe fastener storage device and deliver the fastener through thedelivery conduit.